Compositions using polyuretdione resins

ABSTRACT

The present invention provides a reaction mixture comprising a hot blend of a first isocyanate-based uretdione resin and a second isocyanate-based uretdione resin, a neutralized polyol and a tertiary amine catalyst, and optionally, an additive package selected from the group consisting of flow control additives, pigments (colorants), wetting agents, and solvents, wherein the first isocyanate and the second isocyanate are different. The isocyanate-based uretdiones that have been hot blended together produce coatings, adhesives, castings, composites, and sealants, which exhibit better performance properties (such as microhardness) than those coatings, adhesives, castings, composites, and sealants produced from the constituent isocyanate-based uretdiones alone.

FIELD OF THE INVENTION

The present invention relates in general to polymers, and morespecifically, to polymers made with neutralized polyols, uretdiones andtertiary amine catalysts. The resulting allophanate polymers may be usedto make coatings, adhesives, castings, composites, and sealants.

BACKGROUND OF THE INVENTION

Polyurethane-forming compositions are widely used in a variety ofcommercial, industrial and household applications, such as in automotiveclear-coat and seat cushion applications. Polyurethane systems thatemploy isocyanates which are pre-reacted with monofunctional reagents toform relatively thermally labile compounds are called blockedisocyanates. Uretdiones are a type of blocked isocyanate. Uretdiones aretypically prepared by dimerizing an isocyanate to form uretdione(s) withunreacted isocyanate end-groups which can then be extended with a polyolto form a polymeric material containing two or more uretdione groups inthe polymer chain. In some literature, uretdiones are referred to as“1,3-diaza-2,4-cyclobutanones”, “1,3-diazatidin-2,4-diones”,“2,4-dioxo-1,3-diazetidines”, “urethdiones” or “uretidiones”. Typically,the polymer has few, if any, free isocyanate groups, which is achievedby controlling the stoichiometry of the polyisocyanate, polyol and bythe use of a blocking agent.

The reaction of uretdiones with polyols to form polyurethane coatings iswell known in the art, especially in polyurethane powder coatings.However, the creation of allophanates from uretdiones and polyols atambient or low temperatures in the presence of a tertiary amine catalysthas not been well-studied in the literature. To the best of the presentinventors' knowledge, no one has developed a cross-linking approachusing neutralized polyols to promote successful conversion of uretdioneto allophanate at ambient or low temperatures in the presence oftertiary amine catalysts.

SUMMARY OF THE INVENTION

Uretdione based resins can be crosslinked with polyols to formallophanate groups. Different isocyanate-based uretdiones can be reactedtogether in a flask (hot blended) with a polyol to achieve desiredmolecular weight and functionality. The isocyanate-based uretdiones thathave been blended together produce coatings, adhesives, castings,composites, and sealants, which exhibit better performance than thosecoatings, adhesives, castings, composites, and sealants produced fromthe constituent isocyanate-based uretdiones alone.

Accordingly, the present invention attempts to alleviate problemsinherent in the art by providing such an alternative cross-linkingapproach to obtain compositions having physical properties similar tothose of polyurethane compositions. To increase the conversion rate ofuretdione and polyol to form allophanate groups at ambient or lowtemperatures in the presence of a tertiary amine catalyst, the acidityof the polyol and more generally, the acidity of the system is minimizedor eliminated. Thus, various embodiments of the inventive approachinvolve crosslinking polyuretdione resins with neutralized polyols inthe presence of a tertiary amine catalyst. The polyol may be neutralizedby reaction with an acid scavenger at a temperature ranging from roomtemperature (21° C.-24° C.) to 120° C. The resulting allophanate polymermay be used to make coatings, adhesives, castings, composites, andsealants.

These and other advantages and benefits of the present invention will beapparent from the Detailed Description of the Invention herein below.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described for purposes of illustrationand not limitation. Except in the operating examples, or where otherwiseindicated, all numbers expressing quantities, percentages, and so forthin the specification are to be understood as being modified in allinstances by the term “about.”

Any numerical range recited in this specification is intended to includeall sub-ranges of the same numerical precision subsumed within therecited range. For example, a range of “1.0 to 10.0” is intended toinclude all sub-ranges between (and including) the recited minimum valueof 1.0 and the recited maximum value of 10.0, that is, having a minimumvalue equal to or greater than 1.0 and a maximum value equal to or lessthan 10.0, such as, for example, 2.4 to 7.6. Any maximum numericallimitation recited in this specification is intended to include alllower numerical limitations subsumed therein and any minimum numericallimitation recited in this specification is intended to include allhigher numerical limitations subsumed therein. Accordingly, Applicantsreserve the right to amend this specification, including the claims, toexpressly recite any sub-range subsumed within the ranges expresslyrecited herein. All such ranges are intended to be inherently describedin this specification such that amending to expressly recite any suchsub-ranges would comply with the requirements of 35 U.S.C. § 112(a), and35 U.S.C. § 132(a).

Any patent, publication, or other disclosure material identified hereinis incorporated by reference into this specification in its entiretyunless otherwise indicated, but only to the extent that the incorporatedmaterial does not conflict with existing definitions, statements, orother disclosure material expressly set forth in this specification. Assuch, and to the extent necessary, the express disclosure as set forthin this specification supersedes any conflicting material incorporatedby reference herein. Any material, or portion thereof, that is said tobe incorporated by reference into this specification, but whichconflicts with existing definitions, statements, or other disclosurematerial set forth herein, is only incorporated to the extent that noconflict arises between that incorporated material and the existingdisclosure material. Applicants reserve the right to amend thisspecification to expressly recite any subject matter, or portionthereof, incorporated by reference herein.

Reference throughout this specification to “various non-limitingembodiments,” “certain embodiments,” or the like, means that aparticular feature or characteristic may be included in an embodiment.Thus, use of the phrase “in various non-limiting embodiments,” “incertain embodiments,” or the like, in this specification does notnecessarily refer to a common embodiment, and may refer to differentembodiments. Further, the particular features or characteristics may becombined in any suitable manner in one or more embodiments. Thus, theparticular features or characteristics illustrated or described inconnection with various or certain embodiments may be combined, in wholeor in part, with the features or characteristics of one or more otherembodiments without limitation. Such modifications and variations areintended to be included within the scope of the present specification.

The grammatical articles “a”, “an”, and “the”, as used herein, areintended to include “at least one” or “one or more”, unless otherwiseindicated, even if “at least one” or “one or more” is expressly used incertain instances. Thus, these articles are used in this specificationto refer to one or more than one (i.e., to “at least one”) of thegrammatical objects of the article. By way of example, and withoutlimitation, “a component” means one or more components, and thus,possibly, more than one component is contemplated and may be employed orused in an implementation of the described embodiments. Further, the useof a singular noun includes the plural, and the use of a plural nounincludes the singular, unless the context of the usage requiresotherwise.

In various embodiments, the present invention provides a reactionmixture comprising a hot blend of a first isocyanate-based uretdioneresin and a second isocyanate-based uretdione resin; a neutralizedpolyol and a tertiary amine catalyst; and optionally, an additivepackage selected from the group consisting of flow control additives,pigments (colorants), wetting agents, and solvents, wherein the firstisocyanate and the second isocyanate are different.

In various non-limiting embodiments, the present invention furtherprovides a method of making an allophanate polymer comprising hotblending a first isocyanate-based uretdione resin and a secondisocyanate-based uretdione resin to form a resin hot blend, reacting theresin hot blend with a neutralized polyol in the presence of a tertiaryamine catalyst, optionally in the presence of an additive packageselected from the group consisting of flow control additives, pigments(colorants), wetting agents, and solvents, wherein the first isocyanateand the second isocyanate are different. The polyol may be neutralizedby reaction with an acid scavenger at a temperature ranging from roomtemperature (21° C.-24° C.) to 120° C. Thus, the present inventionprovides a method for producing an allophanate polymer by the followingroute:

In blending uretdiones according to embodiments of the invention, R₁,R₂, R₃, and R₄ may be independently the same or different. The schemeshows the reaction with uretdione from R₁ and R₂ forming an allophanategroup. The second uretdione from R₄ and R₅ does form allophanate aswell. The isocyanate-based uretdiones that have been hot blendedtogether produce coatings, adhesives, castings, composites, andsealants, which exhibit better performance properties (such asmicrohardness) than the respective coatings, adhesives, castings,composites, and sealants produced from the constituent isocyanate-baseduretdiones alone.

As used herein, the term “polymer” encompasses prepolymers, oligomersand both homopolymers and copolymers; the prefix “poly” in this contextreferring to two or more. As used herein, the term “molecular weight”,when used in reference to a polymer, refers to the number averagemolecular weight, unless otherwise specified.

As used herein, the term “polyol” refers to compounds comprising atleast two free hydroxy groups. Polyols include polymers comprisingpendant and terminal hydroxy groups.

As used herein, the term “coating composition” refers to a mixture ofchemical components that will cure and form a coating when applied to asubstrate.

The terms “adhesive” or “adhesive compound”, refer to any substance thatcan adhere or bond two items together. Implicit in the definition of an“adhesive composition” or “adhesive formulation” is the concept that thecomposition or formulation is a combination or mixture of more than onespecies, component or compound, which can include adhesive monomers,oligomers, and polymers along with other materials.

A “sealant composition” refers to a composition which may be applied toone or more surfaces to form a protective barrier, for example toprevent ingress or egress of solid, liquid or gaseous material oralternatively to allow selective permeability through the barrier to gasand liquid. In particular, it may provide a seal between surfaces.

A “casting composition” refers to a mixture of liquid chemicalcomponents which is usually poured into a mold containing a hollowcavity of the desired shape, and then allowed to solidify.

A “composite” refers to a material made from two or more polymers,optionally containing other kinds of materials. A composite hasdifferent properties from those of the individual polymers/materialswhich make it up.

“Cured,” “cured composition” or “cured compound” refers to componentsand mixtures obtained from reactive curable original compound(s) ormixture(s) thereof which have undergone chemical and/or physical changessuch that the original compound(s) or mixture(s) is(are) transformedinto a solid, substantially non-flowing material. A typical curingprocess may involve crosslinking.

The term “curable” means that an original compound(s) or compositionmaterial(s) can be transformed into a solid, substantially non-flowingmaterial by means of chemical reaction, crosslinking, radiationcrosslinking, or the like. Thus, compositions of the invention arecurable, but unless otherwise specified, the original compound(s) orcomposition material(s) is(are) not cured.

As used in the context of the present invention, “hot blended” or “hotblending” means taking a first isocyanate-based uretdione-containingresin and a second isocyanate-based uretdione-containing resin andmixing them together in a flask, reactor, or other vessel, with heatingwhile reacting with the appropriate polyol(s) to obtain a uretdioneblend with specific functionality and molecular weight. The resultinghot blends may be liquid when cooled to room temperature aftercompletion of the reaction.

After the hot blends are made, coatings, adhesives, castings,composites, and sealants formulations are made by addition of theappropriate polyol and catalyst to the blend.

The components useful in the present invention comprise apolyisocyanate. As used herein, the term “polyisocyanate” refers tocompounds comprising at least two unreacted isocyanate groups, such asthree or more unreacted isocyanate groups. The polyisocyanate maycomprise diisocyanates such as linear aliphatic polyisocyanates,aromatic polyisocyanates, cycloaliphatic polyisocyanates and aralkylpolyisocyanates.

Particularly preferred in the present invention are those blockedisocyanates known as uretdiones. The uretdiones useful in the inventionmay be obtained by catalytic dimerization of polyisocyanates by methodswhich are known to those skilled in the art. Examples of dimerizationcatalysts include, but are not limited to, trialkylphosphines,aminophosphines and aminopyradines such as dimethylaminopyridines, andtris(dimethylamino)phosphine, as well as any other dimerizationcatalyst. The result of the dimerization reaction depends, in a mannerknown to the skilled person, on the catalyst used, on the processconditions and on the polyisocyanates employed. In particular, it ispossible for products to be formed which contain on average more thanone uretdione group per molecule, the number of uretdione groups beingsubject to a distribution. The (poly)uretdiones may optionally containisocyanurate, biuret, allophanate, and iminooxadiazine dione groups inaddition to the uretdione groups.

The uretdiones are NCO-functional compounds and may be subjected to afurther reaction, for example, blocking of the free NCO groups orfurther reaction of NCO groups with NCO-reactive compounds having afunctionality of two or more to extend the uretdiones to formpolyuretdione prepolymers. This gives compounds containing uretdionegroups and of higher molecular weight, which, depending on the chosenproportions, may also contain NCO groups, be free of NCO groups or maycontain isocyanate groups that are blocked.

Suitable blocking agents include, but are not limited to, alcohols,lactams, oximes, malonates, alkyl acetoacetates, triazoles, phenols,imidazoles, pyrazoles and amines, such as butanone oxime,diisopropylamine, 1,2,4-triazole, dimethyl-1,2,4-triazole, imidazole,diethyl malonate, ethyl acetoacetate, acetone oxime,3,5-dimethylpyrazole, caprolactam, N-tert-butylbenzylamine andcyclopentanone including mixtures of these blocking agents.

Examples of NCO-reactive compounds with a functionality of two or moreinclude polyols. In some embodiments, the NCO-reactive compounds areused in amounts sufficient to react with all free NCO groups in theuretdione. By “free NCO groups” it is meant all NCO groups not presentas part of the uretdione, isocyanurate, biuret, allophanate andiminooxadiazine dione groups.

The resulting polyuretdione contains at least 2, such as from 2 to 10uretdione groups. More preferably, the polyuretdione contains from 5% to45% uretdione, 10% to 55% urethane, and less than 2% isocyanate groups.The percentages are by weight based on total weight of resin containinguretdione, urethane, and isocyanate.

Suitable polyisocyanates for producing the uretdiones useful inembodiments of the invention include, organic diisocyanates representedby the formulaR(NCO)₂wherein R represents an organic group obtained by removing theisocyanate groups from an organic diisocyanate having(cyclo)aliphatically bound isocyanate groups and a molecular weight of112 to 1000, preferably 140 to 400. Preferred diisocyanates for theinvention are those represented by the formula wherein R represents adivalent aliphatic hydrocarbon group having from 4 to 18 carbon atoms, adivalent cycloaliphatic hydrocarbon group having from 5 to 15 carbonatoms, or a divalent araliphatic hydrocarbon group having from 7 to 15carbon atoms.

Examples of the organic diisocyanates which are particularly suitablefor the present invention include 1,4-tetramethylene diisocyanate,1,6-hexamethylene diisocyanate, 2,2,4-trimethyl-1,6-hexamethylenediisocyanate, 1,12-dodecamethylene diisocyanate, cyclohexane-1,3- and1,4-diisocyanate, 1-isocyanato-2-isocyanato-methyl cyclopentane,1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI), bis-(4-isocyanatocyclohexyl)methane, 1,3- and1,4-bis(isocyanatomethyl)-cyclohexane,bis-(4-isocyanato-3-methyl-cyclohexyl)-methane,α,α,α′,α′-tetramethyl-1,3- and 1,4-xylene diisocyanate,1-isocyanato-1-methyl-4(3)-isocyanato-methyl cyclohexane, and 2,4- and2,6-hexahydrotoluene diisocyanate, toluene diisocyanate (TDI),diphenylmethane diisocyanate (MDI), pentane diisocyanate(PDI)—bio-based), and, isomers of any of these; or combinations of anyof these. Mixtures of diisocyanates may also be used. Preferreddiisocyanates include 1,6-hexamethylene diisocyanate, isophoronediisocyanate, and bis(4-isocyanatocyclohexyl)-methane because they arereadily available and yield relatively low viscosity polyuretdionepolyurethane oligomers.

In some embodiments, the uretdiones may comprise from 35% to 85% resinsolids in the composition of present invention, excluding solvents,additives or pigments. In other embodiments, from 50% to 85% and instill other embodiments, 60% to 85%. The uretdiones may comprise anyresin solids amount ranging between any combinations of these values,inclusive of the recited values.

In various embodiments of the present invention, the reaction mixturecontaining the polyuretdione and the neutralized polyol in the presenceof a tertiary amine catalyst may be heated to a temperature of 140° C.,in other embodiments to a temperature of from 20° C. to 140° C.

The polyols useful in the present invention may be either low molecularweight (62-399 Da, as determined by gel permeation chromatography) orhigh molecular weight (400 to 10,000 Da, as determined by gel permeationchromatography) materials and in various embodiments will have averagehydroxyl values as determined by ASTM E222-10, Method B, of between 1000and 10, and preferably between 500 and 50.

The polyols in the present invention include low molecular weight diols,triols and higher alcohols and polymeric polyols such as polyesterpolyols, polyether polyols, polycarbonate polyols, polyurethane polyolsand hydroxy-containing (meth)acrylic polymers.

The low molecular weight diols, triols and higher alcohols useful in theinstant invention are known to those skilled in the art. In manyembodiments, they are monomeric and have hydroxy values of 200 andabove, usually within the range of 1500 to 200. Such materials includealiphatic polyols, particularly alkylene polyols containing from 2 to 18carbon atoms. Examples include ethylene glycol, 1,4-butanediol,1,6-hexanediol; cycloaliphatic polyols such as cyclohexane dimethanol.Examples of triols and higher alcohols include trimethylol propane andpentaerythritol. Also useful are polyols containing ether linkages suchas diethylene glycol and triethylene glycol.

In various embodiments, the suitable polyols are polymeric polyolshaving hydroxyl values less than 200, such as 10 to 180. Examples ofpolymeric polyols include polyalkylene ether polyols, polyester polyolsincluding hydroxyl-containing polycaprolactones, hydroxy-containing(meth)acrylic polymers, polycarbonate polyols and polyurethane polymers.

Examples of polyether polyols include poly(oxytetramethylene) glycols,poly(oxyethylene) glycols, and the reaction product of ethylene glycolwith a mixture of propylene oxide and ethylene oxide.

Also useful are polyether polyols formed from the oxyalkylation ofvarious polyols, for example, glycols such as ethylene glycol,1,4-butane glycol, 1,6-hexanediol, and the like, or higher polyols, suchas trimethylol propane, pentaerythritol and the like. One commonlyutilized oxyalkylation method is by reacting a polyol with an alkyleneoxide, for example, ethylene oxide in the presence of an acidic or basiccatalyst.

Polyester polyols can also be used as a polymeric polyol component inthe certain embodiments of the invention. The polyester polyols can beprepared by the polyesterification of organic polycarboxylic acids oranhydrides thereof with organic polyols. Preferably, the polycarboxylicacids and polyols are aliphatic or aromatic dibasic acids and diols.

The diols which may be employed in making the polyester include alkyleneglycols, such as ethylene glycol and butylene glycol, neopentyl glycoland other glycols such as cyclohexane dimethanol, caprolactone diol (forexample, the reaction product of caprolactone and ethylene glycol),polyether glycols, for example, poly(oxytetramethylene) glycol and thelike. However, other diols of various types and, as indicated, polyolsof higher functionality may also be utilized in various embodiments ofthe invention. Such higher polyols can include, for example, trimethylolpropane, trimethylol ethane, pentaerythritol, and the like, as well ashigher molecular weight polyols such as those produced by oxyalkylatinglow molecular weight polyols. An example of such high molecular weightpolyol is the reaction product of 20 moles of ethylene oxide per mole oftrimethylol propane.

The acid component of the polyester consists primarily of monomericcarboxylic acids or anhydrides having 2 to 18 carbon atoms per molecule.Among the acids which are useful are phthalic acid, isophthalic acid,terephthalic acid, tetrahydrophthalic acid, hexahydrophthalic acid,adipic acid, azelaic acid, sebacic acid, maleic acid, glutaric acid,chlorendic acid, tetrachlorophthalic acid and other dicarboxylic acidsof varying types. Also, there may be employed higher polycarboxylicacids such as trimellitic acid and tricarballylic acid (where acids arereferred to above, it is understood that the anhydrides of those acidswhich form anhydrides can be used in place of the acid). Also, loweralkyl esters of acids such as dimethyl glutamate can be used.

In addition to polyester polyols formed from polybasic acids andpolyols, polycaprolactone-type polyesters can also be employed. Theseproducts are formed from the reaction of a cyclic lactone such asε-caprolactone with a polyol with primary hydroxyls such as thosementioned above. Such products are described in U.S. Pat. No. 3,169,949.

In addition to the polyether and polyester polyols, hydroxy-containing(meth)acrylic polymers or (meth)acrylic polyols can be used as thepolyol component.

Among the (meth)acrylic polymers are polymers of 2 to 20 percent byweight primary hydroxy-containing vinyl monomers such as hydroxyalkylacrylate and methacrylate having 2 to 6 carbon atoms in the alkyl groupand 80 to 98 percent by weight of other ethylenically unsaturatedcopolymerizable materials such as alkyl(meth)acrylates; the percentagesby weight being based on the total weight of the monomeric charge.

Examples of suitable hydroxy alkyl(meth)acrylates are hydroxy ethyl andhydroxy butyl(meth)acrylate. Examples of suitable alkyl acrylates and(meth)acrylates are lauryl methacrylate, 2-ethylhexyl methacrylate andn-butyl acrylate.

In addition to the acrylates and methacrylates, other copolymerizablemonomers which can be copolymerized with the hydroxyalkyl(meth)acrylates include ethylenically unsaturated materials such asmonoolefinic and diolefinic hydrocarbons, halogenated monoolefinic anddiolefinic hydrocarbons, unsaturated esters of organic and inorganicacids, amides and esters of unsaturated acids, nitriles and unsaturatedacids and the like. Examples of such monomers include styrene,1,3-butadiene, acrylamide, acrylonitrile, α-methyl styrene, α-methylchlorostyrene, vinyl butyrate, vinyl acetate, alkyl chloride, divinylbenzene, diallyl itaconate, triallyl cyanurate and mixtures thereof.Preferably, these other ethylenically unsaturated materials are used inadmixture with the above-mentioned acrylates and methacrylates.

In certain embodiments of the invention, the polyol may be apolyurethane polyol. These polyols can be prepared by reacting any ofthe above-mentioned polyols with a minor amount of polyisocyanate(OH/NCO equivalent ratio greater than 1:1) so that free primary hydroxylgroups are present in the product. In addition to the high molecularweight polyols mentioned above, mixtures of both high molecular weightand low molecular weight polyols such as those mentioned above may beused.

Suitable hydroxy-functional polycarbonate polyols may be those preparedby reacting monomeric diols (such as 1,4-butanediol, 1,6-hexanediol,di-, tri- or tetraethylene glycol, di-, tri- or tetrapropylene glycol,3-methyl-1,5-pentanediol, 4,4′-dimethylolcyclohexane and mixturesthereof) with diaryl carbonates (such as diphenyl carbonate, dialkylcarbonates (such as dimethyl carbonate and diethyl carbonate), alkylenecarbonates (such as ethylene carbonate or propylene carbonate), orphosgene. Optionally, a minor amount of higher functional, monomericpolyols, such as trimethylolpropane, glycerol or pentaerythritol, may beused.

In various embodiments of the invention, the polyol is neutralized, forexample by the addition of an acid scavenger. Acid scavengers should becovalently bonded to the acidic groups within the polyol. In variousembodiments, the acid scavengers may be selected from carbodiimides,anhydrides, epoxies, trialkylorthoformates, amine compounds, andoxazolines. The present inventors believe, without wishing to be boundto any specific theory, that these acid scavengers covalently bind tocarboxylic and acrylic acid groups within the polyols. Such compoundsare commercially available from a variety of suppliers such as forexample, the monomeric carbodiimides sold under the STABAXOL trade namefrom Rhein Chemie, and bis-(2,6-diisopropylphenyl) carbodiimide sold asEUSTAB HS-700 by Eutec Chemical Co., Ltd. In various embodiments, theneutralization is conducted at any temperature ranging from roomtemperature (21° C.-24° C.) to 120° C., in other embodiments from roomtemperature (21° C.-24° C.) to 80° C. and in certain embodiments at roomtemperature (21° C.-24° C.).

In various embodiments of the present invention, the first and secondisocyanate-based uretdiones may be hot blended at various ratios rangingfrom 92:8 to 24:76; in some embodiments the ratio may be 92:8 to 55:45;in yet other embodiments the ratio may be 50:50 and in still otherembodiments the ratio may be from 92:8 to 65:35 depending upon theidentities of the first and second isocyanates.

Examples of suitable solvents include, but are not limited to aliphaticand aromatic hydrocarbons such as toluene, xylene, isooctane, acetone,butanone, methyl ethyl ketone, methyl amyl ketone, methyl isobutylketone, ethyl acetate, butyl acetate, pentyl acetate, tetrahydrofuran,ethyl ethoxypropionate, N-methyl-pyrrolidone, dimethylacetamide anddimethylformamide solvent naphtha, SOLVESSO 100 or HYDROSOL (ARAL),ethers, or mixtures thereof.

The compositions of the present invention may further include any of avariety of additives such as defoamers, devolatilizers, surfactants,thickeners, flow control additives, colorants (including pigments anddyes) or surface additives.

The composition of the invention may be contacted with a substrate byany methods known to those skilled in the art, including but not limitedto, spraying, dipping, flow coating, rolling, brushing, pouring, and thelike. In some embodiments, the inventive compositions may be applied inthe form of paints or lacquers onto any compatible substrate, such as,for example, metals, plastics, ceramics, glass, and natural materials.In certain embodiments, the inventive composition is applied as a singlelayer. In other embodiments, the composition of the present inventionmay be applied as multiple layers as needed.

EXAMPLES

The non-limiting and non-exhaustive examples that follow are intended tofurther describe various non-limiting and non-exhaustive embodimentswithout restricting the scope of the embodiments described in thisspecification. All quantities given in “parts” and “percents” areunderstood to be by weight, unless otherwise indicated. Although thepresent invention is described in the instant Examples in the context ofa coating, those skilled in the art will appreciate it can also beequally applicable to adhesives, castings, composites, and sealants.

The following materials were used in preparing the compositions of theExamples:

POLYOL A an aromatic free, branched hydroxyl-bearing polyester polyol,commercially available from Covestro as DESMOPHEN 775 XP; ADDITIVE A anactive anti-hydrolysis agent for polyester polyurethanes, being used asan acid scavenger for acidic groups within the polyols, commerciallyavailable from Rhein Chemie as STABAXOL I; ADDITIVE B a surface additiveon polyacrylate-basis for solvent-borne coating systems and printinginks, commercially available from BYK Chemie as BYK 358N; CATALYST A1,8-diazabicyclo[5.4.0]undec-7-ene (DBU), tertiary amine catalyst,commercially available from Air Products as POLYCAT DBU; 10% CATALYST Asolution was made in butyl acetate; URETDIONE A a1-isocyanato-3-isocyanatomethyl-3,5,5- trimethyl cyclohexane (isophoronediisocyanate or IPDI)-based uretdione prepolymer, proprietary product ofCovestro LLC, having a uretdione equivalent weight of 1,276 and aviscosity of 817 cPs in 50% butyl acetate; URETDIONE B a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 824 and aviscosity of 8,250 cPs in 30% butyl acetate; URETDIONE C a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 822 and aviscosity of 16,500 cPs in 30% butyl acetate; URETDIONE D a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 820 and aviscosity of 15,300 cPs in 30% butyl acetate; URETDIONE E a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 814 and aviscosity of 8,680 cPs in 30% butyl acetate; URETDIONE F a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 812 and aviscosity of 22,500 cPs in 30% butyl acetate; URETDIONE G a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 808 and aviscosity of 12,900 cPs in 30% butyl acetate; URETDIONE H a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 809 and aviscosity of 9,220 cPs in 30% butyl acetate; URETDIONE 1 a1,6-hexamethylene diisocyanate (HDI) and 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)- based uretdione prepolymer, proprietary productof Covestro LLC, having a uretdione equivalent weight of 808 and aviscosity of 18,800 cPs in 30% butyl acetate; URETDIONE J a1,6-hexamethylene diisocyanate (HDI)-based uretdione prepolymer,proprietary product of Covestro LLC, having a uretdione equivalentweight of 871 and a viscosity of 10,800 cPs in 30% butyl acetate;URETDIONE K a 1,6-hexamethylene diisocyanate (HDI)-based uretdioneprepolymer, proprietary product of Covestro LLC, having a uretdioneequivalent weight of 624 and a viscosity of 31,200 cPs in 20% butylacetate.

Formulations A through K in Table I were prepared following the sameprocedure. As an example, Formulation A was prepared as follows. POLYOLA had been reacted with ADDITIVE A prior to formulation. In a 100 mLplastic container 4.76 parts of the POLYOL A and ADDITIVE A reactionmixture, 0.19 parts ADDITIVE B, 0.98 parts CATALYST A (10% solution inbutyl acetate (n-BA)), 1.70 parts n-butyl acetate, and 32.37 partsURETDIONE A were added. The resulting mixture was mixed using a FLACKTEKspeed mixer for one minute followed by application using a drawdown bar.

Zinc phosphate treated ACT B952, 3″×9″ (7.62 cm×22.9) test panels wereused. Thickness of coatings was 4 mils (100 μm) wet (2 mils (50 μm)dry). The resulting panels were used to test for microhardness.

Films were cured at room temperature (21° C.-24° C.) for one day. Inaddition, films were cured at 100° C. for 30 minutes and allowed tostand for one day at room temperature before testing.

Microhardness (Marten's hardness) measurements were done usingFISCHERSCOPE HM2000 instrument with the method described in DIN EN ISO14577. Microhardness readings were taken under a 20 mN test load run toa maximum of 5 μm indentation depths over a 20-second application time.Results reported are an average of three readings for each formulation.

In Table I, the number in parentheses following the URETDIONE indicatesits functionality.

TABLE I Ex. A Ex. B Ex. C Ex. D Ex. E Ex. F Ex. G Ex. H Ex. I Ex. J Ex.K POLYOL A 4.56 4.96 4.97 4.98 5.01 5.02 5.04 5.03 5.04 4.74 5.56ADDITIVE A 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20 0.20ADDITIVE B 0.19 0.19 0.19 0.19 0.19 0.19 0.19 0.19 0.19 0.19 0.19CATALYST A (solution) 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.98 0.980.98 n-BA 1.70 10.98 10.98 10.98 10.98 10.98 10.98 10.98 10.98 10.9613.78 URETDIONE A (~5) 32.37 URETDIONE B (~5) 22.70 URETDIONE C (~5)22.69 URETDIONE D (~5) 22.68 URETDIONE E (~5) 22.65 URETDIONE F (~5)22.64 URETDIONE G (~5) 22.61 URETDIONE H (~5) 22.62 URETDIONE I (~5)22.61 URETDIONE J (~3.8) 22.94 URETDIONE K (~5) 19.29 Uretdione BlendIPDI/HDI ratio 100/0 92/8 83/17 74/26 65/35 55/45 45/55 35/65 24/760/100 0/100 Microhardness (N/mm²) 1 Day 24.0 86.2 82.7 56.6 13.2 6.0 5.42.9 1.7 0.9 1.0 100° C. 140.3 152.0 151.0 147.6 135.2 134.1 128.5 120.3113.6 6.8 20.2

As can be appreciated by reference to Table I, Examples A through K wereprepared to determine the effect of blending different isocyanateuretdione resin on coating formulation performance in terms ofmicrohardness. Examples A, J, and K were control formulations that werenot formed through resin blends. Examples B, C, D, E, F, G, H, and Iwere hot blended formulations. By comparing microhardness results, it isapparent to those skilled in the art that coatings made fromformulations made with resin blends had better microhardness performancethan the corresponding control formulations.

This specification has been written with reference to variousnon-limiting and non-exhaustive embodiments. However, it will berecognized by persons having ordinary skill in the art that varioussubstitutions, modifications, or combinations of any of the disclosedembodiments (or portions thereof) may be made within the scope of thisspecification. Thus, it is contemplated and understood that thisspecification supports additional embodiments not expressly set forthherein. Such embodiments may be obtained, for example, by combining,modifying, or reorganizing any of the disclosed steps, components,elements, features, aspects, characteristics, limitations, and the like,of the various non-limiting embodiments described in this specification.In this manner, Applicant reserves the right to amend the claims duringprosecution to add features as variously described in thisspecification, and such amendments comply with the requirements of 35U.S.C. § 112(a), and 35 U.S.C. § 132(a).

Various aspects of the subject matter described herein are set out inthe following numbered clauses:

1. A reaction mixture comprising a hot blend of a first isocyanate-baseduretdione resin and a second isocyanate-based uretdione resin; aneutralized polyol and a tertiary amine catalyst; and optionally, anadditive package selected from the group consisting of flow controladditives, pigments (colorants), wetting agents, and solvents, whereinthe first isocyanate and the second isocyanate are different.

2. The reaction mixture according to clause 1, wherein the tertiaryamine is an amidine.

3. The reaction mixture according to clause 1, wherein the tertiaryamine is selected from the group consisting of one selected from thegroup consisting of 1,8-diazabicyclo[5.4.0]undec-7-ene,7-methyl-1,5,7-triazabicyclo[4.4.0]dec-5-ene,1,4,5,6-tetrahydro-1,2-dimethylpyrimidine, 1,2,4-triazole, sodiumderivative and 2-tert-butyl-1,1,3,3-tetramethylguanidine, andcombinations thereof.

4. The reaction mixture according to clause 1, wherein the neutralizedpolyol comprises the reaction product of a polyol and an acid scavenger.

5. The reaction mixture according to clause 4, wherein the acidscavenger is covalently bonded to acidic groups within the polyol and isselected from the group consisting of carbodiimides, anhydrides,epoxies, trialkylorthoformates, amine compounds, oxazolines, andcombinations thereof.

6. The reaction mixture according to clause 4, wherein the polyol isselected from the group consisting of polyalkylene ether polyol,polyester polyols hydroxyl containing polycaprolactones,hydroxyl-containing (meth)acrylic polymers, polycarbonate polyols,polyurethane polyols and combinations thereof.

7. The reaction mixture according to one of clauses 1 to 6, wherein thefirst isocyanate and the second isocyanate are independently selectedfrom the group consisting of 1,4-tetramethylene diisocyanate,1,6-hexamethylene diisocyanate (HDI), 2,2,4-trimethyl-1,6-hexamethylenediisocyanate, 1,12-dodecamethylene diisocyanate, cyclohexane-1,3- and1,4-diisocyanate, 1-isocyanato-2-isocyanato-methyl cyclopentane,1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI), bis-(4-isocyanatocyclohexyl)methane, 1,3- and1,4-bis-(isocyanatomethyl)-cyclohexane,bis-(4-isocyanato-3-methyl-cyclohexyl)-methane,α,α,α′,α′-tetramethyl-1,3- and 1,4-xylene-diisocyanate,1-isocyanato-1-methyl-4(3)-isocyanato-methyl cyclohexane, and 2,4- and2,6-hexahydrotoluene diisocyanate, toluene diisocyanate (TDI),diphenylmethane diisocyanate (MDI), pentane diisocyanate(PDI)—bio-based, and, isomers of any of these.

8. The reaction mixture according to one of clauses 1 to 7, wherein thefirst isocyanate is 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophorone diisocyanate or IPDI) and the second isocyanateis 1,6-hexamethylene diisocyanate (HDI).

9. The reaction mixture according to clause 8, wherein the ratio of1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI) to 1,6-hexamethylene diisocyanate (HDI) is between92:8 and 65:35.

10. One of a coating, an adhesive, a casting, a composite, and a sealantcomprising the reaction mixture according to one of clauses 1 to 9.

11. A method of applying the reaction mixture according to one ofclauses 1 to 10 to a substrate, wherein the method comprises at leastone of spraying, dipping, flow coating, rolling, brushing, and pouring.

12. A method of making an allophanate polymer comprising hot blending afirst isocyanate-based uretdione resin and a second isocyanate-baseduretdione resin to form a resin hot blend, reacting the resin hot blendwith a neutralized polyol in the presence of a tertiary amine catalyst,optionally in the presence of an additive package selected from thegroup consisting of flow control additives, pigments (colorants),wetting agents, and solvents, wherein the first isocyanate and thesecond isocyanate are different.

13. The method according to clause 12, wherein the tertiary amine is anamidine.

14. The method according to clause 12, wherein the tertiary amine isselected from the group consisting of one selected from the groupconsisting of 1,8-diazabicyclo[5.4.0]undec-7-ene,7-methyl-1,5,7-triazabicyclo[4.4.0]dec-5-ene,1,4,5,6-tetrahydro-1,2-dimethylpyrimidine, 1,2,4-triazole, sodiumderivative and 2-tert-butyl-1,1,3,3-tetramethylguanidine, andcombinations thereof.

15. The method according to one of clauses 12 to 14, wherein theneutralized polyol comprises the reaction product of a polyol and anacid scavenger.

16. The method according to clause 15, wherein the acid scavenger iscovalently bonded to acidic groups within the polyol and is selectedfrom the group consisting of carbodiimides, anhydrides, epoxies,trialkylorthoformates, amine compounds, oxazolines, and combinationsthereof.

17. The method according to clause 15, wherein the polyol is selectedfrom the group consisting of polyalkylene ether polyol, polyesterpolyols hydroxyl containing polycaprolactones, hydroxyl-containing(meth)acrylic polymers, polycarbonate polyols, polyurethane polyols andcombinations thereof.

18. The method according to one of clauses 12 to 17, wherein the firstisocyanate and the second isocyanate are independently selected from thegroup consisting of 1,4-tetramethylene diisocyanate, 1,6-hexamethylenediisocyanate (HDI), 2,2,4-trimethyl-1,6-hexamethylene diisocyanate,1,12-dodecamethylene diisocyanate, cyclohexane-1,3- and1,4-diisocyanate, 1-isocyanato-2-isocyanato-methyl cyclopentane,1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI), bis-(4-isocyanatocyclohexyl)methane, 1,3- and1,4-bis(isocyanatomethyl)-cyclohexane,bis-(4-isocyanato-3-methyl-cyclohexyl)-methane,α,α,α′,α′-tetramethyl-1,3- and 1,4-xylene diisocyanate,1-isocyanato-1-methyl-4(3)-isocyanato-methyl cyclohexane, and 2,4- and2,6-hexahydrotoluene diisocyanate, toluene diisocyanate (TDI),diphenylmethane diisocyanate (MDI), pentane diisocyanate(PDI)—bio-based, and, isomers of any of these.

19. The method according to one of clauses 12 to 18, wherein the firstisocyanate is 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethylcyclohexane (isophorone diisocyanate or IPDI) and the second isocyanateis 1,6-hexamethylene diisocyanate (HDI).

20. The method according to clause 19, wherein the ratio of1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI) to 1,6-hexamethylene diisocyanate (HDI) is between92:8 and 65:35.

21. An allophanate polymer made according to the method of one ofclauses 12 to 20.

22. One of a coating, an adhesive, a casting, a composite, and a sealantcomprising the allophanate polymer made according to one of clauses 12to 21.

23. A method of applying the allophanate polymer made according to oneof clauses 12 to 21 to a substrate, wherein the method comprises atleast one of spraying, dipping, flow coating, rolling, brushing, andpouring.

What is claimed is:
 1. A reaction mixture comprising: a hot blend of a1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)-based uretdione resin and a 1,6-hexamethylenediisocyanate (HDI)-based uretdione resin; a neutralized polyolcomprising a reaction product of a polyester polyol and an acidscavenger; and a tertiary amine catalyst selected from the groupconsisting of 1,8-diazabicyclo[5.4.0]undec-7-ene,7-methyl-1,5,7-triazabicyclo[4.4.0]dec-5-ene,1,4,5,6-tetrahydro-1,2-dimethylpyrimidine, sodium-1,2,4-triazolide,2-tert-butyl-1,1,3,3-tetramethylguanidine, and combinations thereof,optionally, a hydrocarbon solvent, optionally, an additive packageselected from the group consisting of flow control additives, pigments,and wetting agents, wherein1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane (isophoronediisocyanate or IPDI)-based uretdione resin and 1,6-hexamethylenediisocyanate (HDI)-based uretdione resin are blended in a weight ratioof between 92:8 and 74:26.
 2. The reaction mixture according to claim 1,wherein the tertiary amine catalyst is1,8-diazabicyclo[5.4.0]undec-7-ene.
 3. The reaction mixture according toclaim 1, wherein the acid scavenger is covalently bonded to acidicgroups within the polyol and is selected from the group consisting ofcarbodiimides, anhydrides, epoxies, trialkylorthoformates, aminecompounds, oxazolines, and combinations thereof.
 4. One of a coating, anadhesive, a casting, a composite, and a sealant comprising the reactionmixture according to claim
 1. 5. A method of applying the reactionmixture according to claim 1 to a substrate, wherein the methodcomprises at least one of spraying, dipping, flow coating, rolling,brushing, and pouring.
 6. A method of making a polymer comprising: hotblending a 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl cyclohexane(isophorone diisocyanate or IPDI)-based uretdione resin and a1,6-hexamethylene diisocyanate (HDI)-based uretdione resin at a weightratio of between 92:8 and 74:26 to form a resin hot blend; reacting theresin hot blend with a neutralized polyester polyol in the presence of atertiary amine catalyst and optionally a hydrocarbon solvent,optionally, in the presence of an additive package selected from thegroup consisting of flow control additives, pigments, wetting agents,wherein the neutralized polyester polyol comprises a reaction product ofa polyester polyol and an acid scavenger and wherein the tertiary aminecatalyst is selected from the group consisting of1,8-diazabicyclo[5.4.0]undec-7-ene,7-methyl-1,5,7-triazabicyclo[4.4.0]dec-5-ene,1,4,5,6-tetrahydro-1,2-dimethylpyrimidine, sodium-1,2,4-triazolide,2-tert-butyl-1,1,3,3-tetramethylguanidine, and combinations thereof. 7.The method according to claim 6, wherein the tertiary amine catalyst is1,8-diazabicyclo[5.4.0]undec-7-ene.
 8. The method according to claim 6,wherein the acid scavenger is covalently bonded to acidic groups withinthe polyol and is selected from the group consisting of carbodiimides,anhydrides, epoxies, trialkylorthoformates, amine compounds, oxazolines,and combinations thereof.
 9. A polymer made according to the method ofclaim
 6. 10. One of a coating, an adhesive, a casting, a composite, anda sealant comprising the polymer made according to claim
 6. 11. A methodof applying the polymer made according to claim 6 to a substrate,wherein the method comprises at least one of spraying, dipping, flowcoating, rolling, brushing, and pouring.